Method and apparatus for producing a decorative surface covering sheet



, w. ROWE 2,775,994 METHOD AND APPARATUS FOR PRODUCING A DECORATIVESURFACE COVERING SHEET 4 Sheets-Sheet 1 Jan. 1, 1957 Filed Feb. 19,1954' INVENTOR.

W QLMLALZQ' Jan. 1, 1957 w ROWE 2,775,994

METHOD AND APPARATUS FOR PRODUCING A DECORATIVE SURFACE COVERING SHEET 4Sheets-Sheet 2 Filed Feb. 19, 1954 I N VEN TOR.

dm FOn/c 9 1. GIMM- w. ROWE 2,775,994 METHOD AND APPARATUS FOR PRODUCINGA DECORATIVE SURFACE COVERING SHEET Jan. 1, 1957 4 Sheets-Sheet 3 FiledFeb. 19, 1954 INIENTOR.

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METHOD AND APPARATUS FOR PRODUCING A oacosmxvs SURFACE COVERING SHEETFiled Feb. 19, 1954 4 Sheets-Sheet 4 I N VEN TOR.

h l/fiqm Rowe M h-Maw HTT'ORNEY United States Patent METHOD ANDAPPARATUS FOR PRODUCING A DECORATIVE SURFACE CGVERlNG SHEET WilliamRowe, Lewiston, Maine, assigner to Bflllllfltlfii Mills, Inc., Lisbon,Maine, a corporation of Maine Application February 19, 1954, Serial No.4I1,475

Claims. (Cl. 154-20) This invention relates to a novel decorative sheetand particularly to a novel decorative surface covering sheet and tomethods and apparatus for producing the same.

One object of the invention is to produce a novel decorative sheetembodying a foundation member and a surface covering layer bonded to thefoundation member and constructed to provide a novel decorative patternon the surface thereof.

A further object of the invention is to provide a novel decorative sheetwhich may be plain, jasp, marbelized, or otherwise decorated with orwithout figures laid lengthwise and/or cross directional, which may beused as a floor or wall covering.

A still further object of the invention is to provide novel, highlyefficient and practical methods by which the present decorative sheetsmay be made.

A still further object of the invention is to provide novel apparatusfor the commercial and efficient manufacture of the present decorativesheets.

In the drawings illustrating more or less diagrammatically the preferredapparatus for producing the present sheet for practicing the presentmethod:

Fig. l is a side elevation of the essential elements of the presentapparatus;

Fig. 2 is an enlarged sectional detail of a portion of the apparatusshown in Fig. 1;

Fig. 3 is a plan view of a portion of the apparatus shown in Fig. 1;

Fig. 4 is a section on the line 4-4 of Fig. 3;

Fig. 5 is an end elevation of the strickler bar;

Fig. 6 is a plan showing the preferred form of the surface design of asurface covering sheet embodying the invention;

Fig. 7 is a similar view showing a modified form of a sheet embodyingthe invention;

Fig. 8 is a cross section of the line 8-8 of Fig. 6;

Fig. 9 is a side elevation of alternative mechanism which may be used toform the elongated flakes; and

Fig. 10 is a plan showing a different design of surface covering sheetembodying the invention.

In general in its broader aspects the invention contemplates afoundation layer of a thermoresponsive material to which flakes of apigmented thermoresponsive material are applied in a random manner andbonded thereto, preferably by heat and pressure to impart a decorativeappearance to the foundation layer and without repeats.

In its preferred form the invention contemplates a decorative sheetcomprising a suitable backing sheet to which a wear-resisting layer isbonded and which covers the backing sheet. The wear-resisting layerpreferably results from the application to the backing sheet of granulesof a pigmented composition and preferably from the application of amixture of a plurality of differently colored granules of pigmentedcompositions imparting a background color and preferably a colored andspeckled appearance to the surface of the wear-resisting layer. Thesurface layer preferably has embedded therein and ice bonded thereto aplurality of and relatively few differently and brightly colored flakes,and preferably a plurality of and relatively few differently andbrightly colored elongated ribbon-like flakes, of a pigmentedcomposition and whose length may vary from a fraction of to about one toseveral inches in length and extend in random directions and in randomspaced relation, and may by proper color combinations stand out instrong contrast to the background imparting an unusual and highlyattractive appearance to the sheet.

The invention in other aspects involves novel methods of producing thepresent decorative and surface covering sheets as well as novel andhighly efficient apparatus for economically producing the same.

For purposes of illustration the invention will be described inconnection with the production of a decorative surface covering sheet inthe nature of linoleum and other flooring materials of the granulatedtype. The present sheet includes a base or backing member which maycomprise paper, treated or untreated felt and textile fabrics, such ascotton or burlap, plastic, rubber or rubber-like sheet materials and anyother suitable backing to which a wear-resisting composition may bebonded. The treated felt may be saturated with any one of a number ofsaturants including asphalts and natural or synthetic resin vehicles. Ifdesired to improve the appearance, a smoothing coat consisting of anoleoresinous binder or synthetic resin combined with a latex, such asbutadiene styrene copolymer and the like, with fillers may be appliedover the saturated felt. This smooth ing coat may be sensitive to heatand pressure to improve the bond of the composition to the saturatedfelt. A sticky coat without filler may also be applied as a face coatover a suitable backing to obtain better bond of the composition to thefelt. A sticky coat which is unaffected at room temperature butsensitive to heat and pressure may be used. Acrylonitrile butadienecopolymers or coumarone indene resins or a combination of both and thelike may be used. Such a backing layer is provided with a surfacecovering layer, preferably of the granulated type, such as is nowcommonly used in the production of linoleum or in the production of anyof the other granulated types of floor and surface coverings now on themarket. Preferably, the wear-resisting layer may be produced by theapplication to the surface of the backing sheet of a layer of granuleseach consisting of a pigmented thermoresponsive composition comprising abinder, pigment and filler. The granules may be of one color or amixture of colors so that when applied to the sheet and subsequentlycalendered or pressed under heat and pressure or otherwise formed into asmooth wear-resisting layer of one or more colors or of speckledappearance of one or many colors is produced.

In accordance with the present invention provision is made for greatlyenhancing the decorative appearance of the covering sheet thus fardescribed by embedding in and bonding to the same in a scattered patternand in random spaced relation a series of brightly colored flakes andpreferably a series of flakes in brightly colored elongated narrowribbon-like form. These may be of varying lengths producing a scatterpattern, such as is illustrated in Figs. 6 and 10. These narrowelongated ribbon-like flakes may be produced and applied to theaforesaid surface covering layer in a novel manner in accordance withthe present invention and prior to the calendering or press ing thereofso that when the sheet is calendered or subjected to the pressingoperation such flakes are embedded in and bonded thereto and form anintegral part of the final product, imparting thereto a novel and highlydecorative appearance. Provision is also made in accordance with thepresent invention for controlling the production and application of theribbon-like flakes in such a manner that flakes of different size and indifferent patterns may be applied to the sheet, as will be described.

Referring now to the drawings, 10 represents the base or foundationsheet upon which the granulated thermoresponsive layer 12, which will behereinafter referred to as the background layer, may be produced as willbe described. In producing the individual granules a plastic binder iscombined with the required color pigments, preferably together withfillers, such as wood flour and whiting, and a typical formula forproducing the granulated plastic composition is as follows:

Pounds Binder 200-400 Wood flour 200-500 Whiting 300- Pigments (whiteand colored pigments) 20-100 A preferred formula is as follows:

Pounds Binder 335 Wood Flour 400 Whiting 100 Pigment 40 The binder,which as will be hereinafter pointed out, may be of any usual orpreferred composition, such as an oleroesinous binder or a gelledlinseed oil or other siccative oil gels produced by oxidizing thesiccative oil to a gel in any usual or preferred form of kettle, such asin a modified Bedford kettle, and after the binder has been produced itis preferably placed in a mixing apparatus of any usual or preferredform, such as in a Banbury mixer, where it is combined with the fillersand pigments and worked into a uniform mass by the operation of themixers. After having been formed, the binder composition is thenpreferably fed into a disintegrator (not shown) of any usual orpreferred form, and in practice one form of suitable disintegrator mayconsist of two cages, one driven inside the other, and which are rotatedin opposite directions at a high rate of speed. The pigmented bindercomposition is fed into the inner cage, and the high speed shatters thecomposition into very small granules.

In practice it is preferred to produce the different colored granulesseparately and to subsequently blend them if desired to produce thedesired color blend so that the background layer, indicated at 12, ofthe surface covering sheet may have a predetermined color andappearance. This background layer may be of one color or may be of ablend of a series of different colored individual granules, imparting tothe background a speckled appearance similar in some degree to theapperance which might be produced by the application of fine differentcolored confetti. The effect produced by the use of a plurality ofcolored particles in producing the background surface may be afoundation color, such for example as red, green, yellow or blue, andalso may be black or white, over which extremely small particles 15 ofone or more colors are distributed in a more or less uniform manner overthe surface of the sheet.

In producing the foundation layer instead of using the conventionalstencilling equipment or stencil openings or screens used inconventional machines for producing inlaid linoleum to apply theplurality of colors on the sheet, in accordance with the presentinvention the particles are fed behind one or more oscillating bars 20which will be hereinafter referred to as stricklers. The strickler bars20 may be driven from a motor 21 through an eccentric connection 22. Theoscillating strickler bars may and preferably will be provided withmicrometer adjustments (not shown) at each side of the sheet to enableaccurate adjustment of the height of the undersurface of the bar fromthe sheet so that the desired thickness of granular layer may beproduced over the surface of the sheet as the sheet travels under thebar and the bar is reciprocated.

In order to prevent the colored particles from sticking together andpermit free flow (similar to dry sand) a small percentage of talc orsimilar material is added to the blended colored granules. It has beenfound that approximately 1 to 5% talc based on the compound is desirable. It is also desirable to add the tale to the blended colorgranules as shortly before they are applied to the base sheet aspractical.

After the sheet with the granulated surface constituting the foundationor background layer has been applied, the base sheet now moves forwardtoward the press, and the next step in the operation involves theproduction of and the application of the flakes 25, preferably of formindicated in Fig. 6, but which for some purposes may take the formindicated at 26 in Fig. 7.

As the base sheet containing the loose fluffy particles from which thebackground layer is produced moves forward toward the press the flakes25 are applied to the surface. This is accomplished by feeding thedisintegrated pigmented composition or if desired a scratch pigmentedcomposition without disintegration into a two-roll mill 30. The rolls31, 32 of the mill operate at differential speeds, and it is preferredto use different temperatures on these rolls 31, 32 in order to have thecomposition stick to the colder roll 32. Even speed rolls may be usedand the difference in temperature alone utilized to cause thecomposition to stick to the colder roll. Preferably, the rolls 31, 32are divided into a plurality of sections 40 by grooves 42, and granularcompositions of different colors are preferably fed into these sectionsutilizing a divided hopper and cheek plates (not shown) to obtain thedifferent and preferably desired colored compositions on each section 40of the roll 32. The cheek plates fit into the depressions in the rollsto avoid overlapping of colors and blending of the colors and theproduction of half-tones. The application of pressure between the rollscauses the composition to form as a uniform layer on the roll 32 asdescribed, and provision is then made for shaving off the composition ateach section of the roll by a series of small cutters 45. These cuttersmay take various forms, and in effect operate to shave off apredetermined thickness of material from each section of the roll 32 inthe form of an elongated ribbon-like flake or strip. This shavingoperation imparts irregular conformation to the ribbon-like flakesgiving the appearance of a worm. As these elongated strips or flakes 25descend they are subjected to the action of a rapidly moving revolvingcutter member which severs the strips to the desired length. Theseworm-like flakes 25 may be varied in width, thickness and lengthaccording to the decoration or design which it is ultimately desired toproduce on the surface of the sheet. After the short flakes or strips 25have been produced they are permitted to fall through a hopper 52 onto atransversely travelling belt 54 by which they are moved across and abovethe surface of the base sheet 10 which is advancing thereunder.

Alternate apparatus is illustrated in Fig. 9 which may be used inproducing suitable elongated ribbon-like flakes and essentially, suchapparatus may comprise a rotated roll 53 having a fixed shoe 55 extendedaround a portion of the same. The face of the shoe gradually tapersdownwardly so that when granules of the pigmented composition are fed asillustrated between the shoe and the roll, the granules are rolled outinto elongated pencil-like elements which preferably drop on thetransverse conveyer or belt 54 to be moved across and above the basesheet 10 in a manner similar to that illustrated in Fig. 4. The size ofthe granules fed into the apparatus may be used to control the lengthand thickness of the pencil-like flakes.

Provision is preferably made for projecting the ribbonlike flakes 25from the surface of the belt and moving them in the direction of theadvance of the base sheet 10, and as herein shown, a helical or sinuousform of brush is utilized to brush off these shot ribbon-like flakes 25at a rapid rate and to project them through the air forwardly;preferably. against a curtain or stop-mem ber 65 by which the forwardmovement 'of the-flakes'ZS isended, and the-flakes arep'ermitted to fallby gravity onto the surface of-the granulated layer of the base sheet10. Othermethods may be used if found desirable in controlling theapplication of the flakes to the surface of the base sheet. The effectof the brush is to throw the flakes forward, and control of theuniformity of the pattern ofthe flakes on the sheet may be obtained byusing compressed air which is applied from one or more nozzles 71 in thesame general direction as the conveyer belt moves. The curtain 65 isplaced several feet in front of the sine curve brush and operates tostop the flakes as they fly through the air. The flakes hit the sheetand drop to the surface of the moving base sheet 10.

After the flakes 25 have been applied to the granular layer upon thebase sheet as above described, the compositesheet in this condition isconducted around a heated press or calender roll 70, heated toa degreesufficient to amalgamate the granules to one another, with thesimultaneous application of pressure by'tbe presser rolls 72. Anysuitable form of pressing apparatus may be used, including for example,rotary presses, hydraulic presses and pressure calenders. The pressureserves to embed the flakes 25 into the granular layer, and the combinedeffect-of heat and pressure bonds the granules to one another and to thebacking sheet and bonds the flakes to the granular layer so that asatisfactory unitary wear-resisting,

decorative layer is produced on the backing sheet. Thereafter, dependingon the character of the composition used in the production of thegranules and flakes, the composite sheet may beled' from the pressorcalender to a curing or drying oven 74 following the usual practiceemployed in the floorcovering art.

Instead of the fiat thin ribbon-like elongated flakes, flat particles orirregular shapes which are normally larger than the disintegratedfluffyparticles used for the base are produced by permitting the tworolls on the roll mill tocome to a closer clearance. The shavers andrapidly revolving cutters are removed. As the thin sheets of differentcolors leave the rolls, they may be fed into a breaker and screen (notshown) to form flat irregular shaped particles or flakes 26 and fed tothe belt'conveyer and brushed off by the sine curve brush as describedabove.

An alternative method for producing the flakes 25 may be two beltstravelling in the same direction with a differential speed; in otherwords, one belt is travelling faster than the other. The granulatedcomposition is fed in betweenthe belts to form the elongated ribbon-likeflakes 25 which are dropped through a funnel on top of the conveyer beltand applied on the granulated base sheet by means of a sine curve brush,as above.

As above described, the composition and a granulated surface are finallypressed and hung into festoons in a stove and cured (except vinyl andrubber compositions) after which the' material may be coated withlacquer or an equivalent clear coat'applied in any known or preferredmanner, waxed if desired, and trimmed to the desired width and rolledfor shipment and use. The finished goods may also be cut into tile ofvarious sizes. It may be desirous in some cases, such as vinyl flooringor rubber flooring, to eliminate the use of lacquer or equivalent clearcoat or wax.

If desired the foundation layer may be produced as one operation and theflakes produced and applied as a separate operation. A pressingoperation may be utilized in the production of the foundation layerand/or in the application of the flakes. Thereafter the product is ledto the drying oven and cured.

In producing a binder suitable for the production of the individualgranules of which the background surface of the present decorative sheetmay be produced as above described, I may utilize a linoleum cementhaving'as its base an oxidized linseed oil prceessedi inaccordancewith-the methodswell known in the'artin' the and the like,produced by oxidizing the siccative oil to a gel in'a modified Bedfordkettle.

The binder may also contain a plasticized vinyl resin. For example,binders which are of the preferred type consisting of gelled linseedoil, plasticized vinyl resin and a binder as shown in United'StatesPatent No. 2,630,319 are as follows:

Pounds Siccative oil gel 0 to 100 Plasticized'vlnyl resin 0 to 150Binder U. S. Patent No. 2,630,319 350 to 150 Other binders may includethe following:

Pounds Siccative oil Plasticized vinyl resin 55 Binder 200 Pounds Vinylresin 55 Binder 280' III Pounds Siccative oil gel 80 Plasticized vinylresin Binder 165 Pounds Paracoumarone indene resin 21 Cottonseed pitch14 Asbestos medium fiber 45 Asbestine l0 Floated silica 5 Color pigment5 Tile formula 18 lbs. paracoumarone indenelight grade 15 lbs. stearinepitch M. P. approximately -140 F. 4 lbs. blown castor oil 30 lbs.limestone 66 lbs. short asbestos fibers Pigment as required.

The foregoing are representative formulas for asphalt tile. The formulasshown above are examples only and can be varied in composition. Stearinepitch may be replaced partially or entirely with cottonseed pitch, soyabean pitch, linseed pitch and the like. For darker colors gilsonitesynthetic or natural may be used, or asphalt processed by oxidation orsteam refining. Blown castor oil may be replaced with other blown oils,such as blown linseed, blown soya, softer pitches, high molecular weightpolymers produced from hydrocarbons of predominately aromatic structure,or various chemical plasticizers, such as dioctyl phthalate, tricresylphosphate and the like.

These compositions are thermoplastic in nature and are non-oxidizing anddo not require curing. After the material is pressed it is ready for themarket.

The fillers instead of being limestone, may be replaced with silica,barytes, blanc fixe, magnesium silicate, aluminum silicate, asbestineand the like,

If grease resistant tile is desired the paracoumarone indene resin maybe replaced with thermoplastic hydrocarbon resins produced from styrenetype materials which also contain homologues of styrene and substitutedstyrene. Piccolastic resins produced by Pennsylvania Industrial ChemicalCorporation with a melting point of approximately 125 F. are mostdesirable. A low molecular weight polystyrene may be added with theparacoumarone indene resin if desired to obtain grease resistance.

A good example of the polystyrene that can be used is produced byKoppers Company, Inc. with the following properties:

Ball and ring softening point 144-148 C. Viscosity 30% solution intoluene (Brookfield viscometer) 69-69 cps. Volatile matter (110 C. for 3hrs.) Less than 2% Monomer content Less than 1% The plasticized vinylresin may be prepared as follows:

Pounds Vinyl chloride vinylidene copolymer 100-200 Dioctyl phthalate 50-25 Dibasic lead phosphite 8- 4 Dibasic lead stearate 2- 1 H PoundsPolyvinyl chloride 100-200 Dioctyl phthalate 50- 25 Dibasic leadphosphite 8- 4 Dibasic lead steal-ate 2- 1 HI Pounds Vinylchloride-vinyl acetate copolymer 100-200 Dioctyl phthalate 50- 25Dibasic lead phosphite 8- 4 Dibasic lead stearate 2- 1 Other vinylresins may be used, such as polyvinyl acetate, polyvinyl butyral, blendsof vinyl chloride and butadiene acrylonitrile. Various polystyreneresins including resins produced from styrene type materials containinghomologues of styrene and substituted styrene may be used as a partialreplacement of the vinyl resins.

Plasticizers other than dioctyl phthalate may be used, such as dibutylphthalate, butyl benzyl phthalate, tricresyl phosphate, triphenylphosphate, alkyd aryl phosphate, di-iso-octyl phthalate, dibutoxyethylphthalate. polyester plasticizers of the oil modified alkyd type andresin types based on sebacic acid and related materials and the like maybe used.

Other stabilizers for both heat and light may be used, such as bariumcadmium laurate, barium cadmium ricinoleate, cadmium 2 heXyl hexoate orother lead compounds may be used. Organic tin compounds or stabilizerswith epoxide type resins may be used.

The amount of plasticizer used may be varied as shown above as well asthe amount of stabilizer used.

The fillers may also be varied. Instead of calcium carbonate, calciumsulphate, barytes, blanc fixe, magnesium silicate, mica, clay andasbestine may be used,

The wood flour used may be either soft wood or hard wood. A fibrouschemically purified wood cellulose with a high alpha cellulose contentmay be used. Some semichemically purified wood fiber, such as the typeproduced in an Asplund defibrator, may be used. Other sources of organicfibers include cork, ground walnut shells, ground almond shells, andothers.

Inorganic fibers, such as asbestos, glass fiber or glass iii) wool, maybe used as a of the organic filler.

Although I show a preferred granulated composition for the base or theflakes, other formulas may be used, such as vinyl asbestos compositions.Typical formulas partial or complete replacement which may be used areas follows:

Pounds Vinyl chloride-vinyl acetate copolymer S4 Dioctylphthalate 40Calcium carbonate 100 Asbestos 147 TiOz 20 Stabilizer 8 Stearic Acid 1II Pounds Vinyl chloride vinyl vinylidene copolymer 100 Asbestos 125Calcium carbonate 120 TiOa l Dibutyl phthalate 10 Butylbenzyl phthalatel Stabilizer Stearic acid 1 In Pounds Polyvinyl chloride 100 Tricresylphosphate 25 Butylbenzyl phthalate 23 Asbestos 100 Calcium carbonate 250TiOz Stabilizer 5 Stearic acid .5 IV

Pounds Neolyn resin (a rosin derived alkyd material) 15 Polyvinylchloride 60 Tricresyl phosphate 25 Stabilizer 5 Calcium carbonate 80Asbestos 10 T1011 10 v Pounds Neolyn (a rosin derived alkyd material)Vinyl chloride vinyl vinylidene copolymer Tricresyl phosphate 10Stabilizer 5 Calcium carbonate Asbestos 10 T102 10 VI Pounds Neolynresin 43 Vinyl chloride vinyl acetate copolymer 43 Di-iso-octylphthalate l4 Stabilizer 4 Calcium carbonate 80 Asbestos 10 TlOa 10quired for the vinyl combe modified especially in e type of plasticizerused 9 ing: or panelingpr walLcovering sheet may be'used of which thefollowing are illustrative formulas:

II III Pounds Pounds Pounds Rubber (synthetic or natural) 100 100 SReclaimed 40 Reogen (011 soluble snlfonlc acid 01 gb molecular Weightwith parafine oil) 2 2 2 Stoal'lc A01 e .6 .5 .5 Coumarone IndeneResin... 2 2 2 Agertte Wlilte "(anti-oxidant) .5 .5 Zinc Oxide". 3 3 3Filler and Pigme 30 100 75 Sulphur; 2. 5 2.6 2. 5 Alta-x (benzothialyldisulfide] 6 6 .6 Captax (mercaptobenzothiazole) 6 .6 6 Methyl Zlmate 0.12 0.12 0. 12

Material is compounded, scratched and processed, as indlcated in theabove write-up. However, the final sheet after the application of thedecorative flakes is normally vulcanized for cure.

Forsome purposes lrnay prefer to produce the granulated composition forthe production of the base or foundation sheet or for the production ofthe flakes which are appliedthereto, in accordance with the presentinvention, of'a' binder of a fire-resistant nature. Accordingly, anyknown or preferred fire-retardant therrnoresponsive compositions whichpossess suitable characteristics may be used for this purpose.

Pounds Gelled'linseed oil 66.0 70% chlorinatedparafin" 46.4 42%'chlorinated parafiin 19.7 Antimony trloxide 104.0 Asbestos 116.0Magnesium: silicate- 122.5 Coloring matterflnn 45 .0 Dibasicleadphosphite; 3.3 Zinc oxide 0.5 Manganese resinate (6% min.) 0.04 HPounds Gelled linseed oil 66.0 70% chlorinated parafiin 46.4 42%chlorinated paraifin 19.7 Antimony trioxide 130.0 Asbestos 116.0Magnesium'silicate 96.5 Coloring matter 45.0 Dibasic lead phosphite 3.3Zinc oxide 0.5 Manganese resinate (6% min.) 0.04 In Pounds Gelledlinseed oil 66.4 70% chlorinated parafiin 46.4 42% chlorinated parafiin19.7 Antimony trioxide 104.0 Asbestos 116.0 Aluminum silicate 122.5Coloring matter 45.0 Dibasic lead phosphite 3.3 Zinc oxide a- 0.5Manganese resinate (6% min.) 0.04 IV Pounds Gelled linseed oil 66.4 70%chlorinated parafiin 46.4 42% chlorinated paraflin 19.7 Antimonytrioxide 130.0 Asbestos 116.0 Aluminum silicate 96.5 Coloring matter45.0 Dibasic lead phosphite 3.3 Zinc oxide 0.5 Manganese resinate (6%min.) 0.04

Pounds Vinyl resin-siccative oil gel (1 to l) 114.5 Antimony oxide52-156 Asbestos 55 Aluminum silicate 2685-1645 Coloring pigment 30.0Zinc oxide 0.4 Manganese resinate 0.03 Lead phosphite 3.0 VI PoundsVinyl resin-siccative oil gel (1 to 1) 131.3 Aroclor 1262 (Chlorinatedbiph'enyl) 18.7 Asbestos 117.5 Magnesium silicate 250.0 T102 (titaniumdioxide) 29.0 Lead phosphite 4.0 Pounds Linseed gel 45.0 70% chlorinatedparaffin 48.0 Vinyl chloride-vinyl acetate copolymer 40.0 Tricresylphosphate 40.0 Lead phosphite 5.0 Antimonyoxide 54.0 Magnesium silicate214.0 Coloring matter 27.0 Zinc oxide 1.35 Manganese resinate 0.03 VIIIPounds Linseed gel 37.0 70% chlorinated paraffin 48.0 Antimony oxide54.0 Magnesium silicate 150.0 Barium sulphate 54.0 Vinyl chloride-vinylacetate copolymer 40 Di-octyl phthalate 60 Coloring matter 27 Leadphosphite 4.5 Zinc oxide 1.12 Manganese resinate 0.03

IX Pounds Linseed gel 66.0 70% chlorinated paraffin 46.4 42% chlorinatedparaffin 19.7 Antimony oxide 157.0 52.2 Asbestos 116 Magnesium silicate695-1743 Color pigment 45.0 Lead phosphite 3.5 Manganese resinate 0.04Zinc oxide 0.5

Various modifications of the illustrated apparatus may in practice beutilized in producing the present products.

Thus, if desired any of the known or preferred designs maybe produced onthe foundation layer prior to the application of the flakes inaccordance with the present invention, as by the use of stencils orscreens following prior art method. Thereafter the flakes may be appliedand bonded to the foundation layer as above described. The stencils mayembody divided sections to permit the application of plain or difierentcolored granules, or granules of a plurality of colors, in the differentsections according to the background effect that it may be desired toproduce on the foundation layer, and thereafter the flakes may beapplied as above described.

Instead of the strickler unit shown a divided strickler unit may be usedwherein provision is made for applying one or more bands, either plainor colored, and of any desired width, and thereafter the tlakes may beapplied as above described.

In order to form flakes of varying colors a plurality of sets of rolls30 without subdivisions may be used in tandem with each roll suppliedwith its own colored material.

An alternative method which may be used in the production of the flakesand particularly the elongated ribbonlike flakes may include the use ofany known or preferred form of extrusion apparatus similar to thatextensively used in producing flat and round plastic shapes, and abreaker mechanism for reducing the extruded shapes to smaller flakes.

Also, instead of the sine curve brush which is in the illustratedapparatus, other means may be employed for projecting the flakes ontothe foundation or base sheet, as for example the flakes may be blown orcaused to drop onto an oscillating or vibrating screen and to then fallat random onto the base sheet.

In some instances I may prefer to utilize a thermoresponsive carriersheet or web without any backing, such as a web or sheet of thecomposition used in the production of the various tiles, such as asphaltand vinyl tiles, and the flakes may be applied directly thereto or to alayer of thermoresponsive granules applied to the carrier sheet.Following application of the flakes, the composite sheet may besubjected to a pressing operation, or if desired a series of sheeterrolls may be used to gradually decrease the thickness and embed theflakes, preferably utilizing heat to combine the components into aunitary product. When the flakes are applied to a thermoresponsivecarrier sheet, such as the asphalt or vinyl tile sheet, the latter mayhave a plain or mottled surface, or bands simulating the appearance ofhardwood floors, borders or any other desired designs may be provided onthe base sheet, preferably followed by the application of the flakes inaccordance with the procedures outlined above.

In some instances I may prefer to apply to a thermoresponsive carriersheet, color in the form of pigmented granules of a thermoresponsivecomposition which is capable of bonding with the thermoresponsivecarrier sheet, such as a sheet from which any of the commercial forms ofasphalt or vinyl tiles are formed, and the colored granules may andpreferably will be applied by either a sectional type of reciprocatingstrickler bar or by a series of individual smaller strickler barsdisposed to apply the colored granules in the form of bands over thesurface of the thermoresponsive carrier sheet, and in this mannereffects, such as borders and appearances simulating hardwood floors, maybe produced, and in addition, such banded products in the form of tilesmay be laid to simulate parquet floors.

From the description thus far it will be observed that the pigmentedcomposition, of which the wear-resisting surface layer and the flakesare made may be of any color and may be black or White. It will also beobserved that the following types of compositions may be used for thesepurposes, namely, an oxidizable composition, such as a linoleumcomposition; a vulcanizable composition, such as a rubber or rubber-likecomposition; a thermoplastic composition of which the vinyl resins andasphalt tiles are typical; a two-stage thermosetting composition whichis characterized by a softness when heated to moderate temperatures andwhich may be converted or set up into a hard mass when subjected tosubstantially higher temperatures. Typical of such materials are thetwo-stage Bakelite resins and Epon resins now on the market. Inaddition, combinations of oxidizable and thermosetting compositions maybe used. It will also be observed by reference to Figs. 6 and 10 thatthe elongated ribbon-like flakes may be aptly described as twigs ortwig-like. l t will also be observed that by reason of the randomapplication of the flakes in accordance with the preferred andillustrated method, no repeats are produced in the decorative designproduced by the flakes.

Having thus described the invention, what is claimed is:

l. in the method of producing a decorative sheet of the characterdescribed, which consists in feeding a plurality of different coloredmasses of the pigmented com position onto successive portions of a setof calender rolls whereby to produce on one of the rolls a plurality ofdifferent colored sheets of plastic composition disposed along thesurface of the roll, and then holding a plurality of narrow cuttersadjacent each of said portions of the roll and substantially in ahorizontal plane passing through the axis of the roll whereby to shavefrom each a plurality of different colored elongated strips thuspermitting said strips to fall by gravity out of contact with the rolland without coalescence with other strips, and during their descentsubjecting the strips to a cutter to cut the strips into shorterribbon-like flakes, collecting the descending flakes on the surface of abelt, advancing a foundation sheet having a granulated surface undersaid belt, then projecting said flakes from the surface of the beltthrough the air and onto the surface of the granulated sheet to producea scattered pattern of different colored worm-like plastic strips on thesurface thereof, and then subsequently subjecting the composite coveredsheet to heat and pressure to embed the wormlike strips in the surfaceand to consolidate the whole into a unitary layer.

2. The method as defined in claim I wherein the flakes are projectedlongitudinally of the advancing sheet in the direction of travel thereofagainst a curtain, and then permitted to drop onto the surface of thegranular layer to form a scattered pattern.

3. In the method of making a decorative sheet, the steps comprisingadvancing a backing sheet covered with a granular composition, feeding aplurality of different colored masses of pigmented composition ontosuccessive portions of a rotating roll whereby to produce on the roll aplurality of different colored sheets of plastic composition spacedaxially along said roll, then holding a plurality of narrow cuttersadjacent each of said portions of the roll and substantially in ahorizontal plane passing through the axis of the roll whereby to shavefrom each a plurality of different colored elongated strips thuspermitting said strips to fall by gravity out of contact with the rolland without coalescence with other strips, and during their descentsubjecting the strips to a cutter to cut the strips into shorterribbon-like flakes, collecting the descending flakes on the surface ofthe belt, advancing a foundation sheet having a granular surface undersaid belt, and then projecting said flakes through the air onto thesurface of the granular covered sheet to produce a scattered pattern,and then subsequently subjecting the composite sheet to pressure toembed the ribbon-like flakes into the surface and to consolidate thewhole into a unitary sheet.

4. Apparatus for producing a decorative sheet of the characterdescribed, comprising means for supporting and continuously advancing abacking web, means for depositing a pigmented composition in granularform upon the backing web as it advances, a reciprocable strickler barextending transversely of the backing sheet for operating on thegranular mass to spread it to a uniform thickness evenly over thebacking sheet, means for pressing the granulated surface into a unitarylayer and for bonding it to the backing sheet, means for forming andapplying flakes of pigmented composition in a scattered pattern oversaid granular layer prior to its passage to said pressing means, saidflake forming means comprising a pair of cooperating rolls, means forfeeding a plurality of different colored masses of a pigmented plasticcomposition between said rolls whereby to produce on one of the rolls aplurality of different colored sheets of plastic composition disposedalong the surface of the roll, a plurality of narrow cutters, means forsupporting the cutters whereby to dispose the same adjacent each of saidcolored sheets of plastic on the surface of the roll and with thecutters lying substantially in a horizontal plane passing through theaxis of the roll whereby to enable a plurality of different coloredelongated strips to be shaved from the roll and to be permitted to fallfreely without coalescence with other strips, a cutter below said narrowcutters and in the path of the descending plastic strips for cutting thestrips into shorter ribbon-like flakes, a belt disposed below saidcutters and in a position to collect the descending flakes on thesurface of the belt, a brush for projecting said flakes on the surfaceof said belt through the air and onto the surface of the granulatedsheet to produce a scattered pateern of different colored worm-likeplastic strips on the surface thereof, and mean for subsequentlysubjecting the composite sheet to heat and pressure to embed theworm-like strips in the surface and to consolidate the whole into aunitary layer.

14 5. Apparatus as defined in claim 4 wherein a curtain is disposed inthe path of the flakes being projected through the air to be engaged bysaid flakes and permit the flakes to fall freely on the granular surfaceof the 5 foundation sheet.

References Cited in the file of this patent UNITED STATES PATENTS469,240 Godfrey et a1. Feb. 23, 1892 10 2,341,651 Raschigg Feb. 15, 19442,478,885 Alvey Aug. 9, 1949

